US5485737A - Apparatus for hydroforming a vehicle manifold - Google Patents
Apparatus for hydroforming a vehicle manifold Download PDFInfo
- Publication number
- US5485737A US5485737A US08/408,742 US40874295A US5485737A US 5485737 A US5485737 A US 5485737A US 40874295 A US40874295 A US 40874295A US 5485737 A US5485737 A US 5485737A
- Authority
- US
- United States
- Prior art keywords
- die
- die set
- tube
- stamping
- tubular member
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D9/00—Bending tubes using mandrels or the like
- B21D9/15—Bending tubes using mandrels or the like using filling material of indefinite shape, e.g. sand, plastic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D9/00—Bending tubes using mandrels or the like
- B21D9/08—Bending tubes using mandrels or the like in press brakes or between rams and anvils or abutments; Pliers with forming dies
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49398—Muffler, manifold or exhaust pipe making
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49805—Shaping by direct application of fluent pressure
Definitions
- This invention relates to a process for forming the tubular members of a vehicle manifold and, in particular, to forming the compound curvatures of the tubular member using cooperating die sets and a hydroforming process to maintain an internal fluid pressure preventing deformation of the tube during bending.
- Sheet metal may be stamped and stretched to form the desired configuration.
- Tubular blanks have been bent, stretched and radially expanded to form complex configurations.
- crimping or buckling may occur at the inner radius of the bend.
- the inner radius has been supported to guide the compression at the inner surface as the outer surface is stretched. Nevertheless, even with support certain configurations simply cannot be formed without deformation of the tubular member.
- Hydroforming of metal components was developed to alleviate the deformation of the metal during bending, stretching, etc. into complex configurations.
- the general principal of hydroforming comprises applying a predetermined fluid pressure to an area of the metal to be manipulated.
- an internal fluid pressure is applied as the tube is bent and stretched.
- this is accomplished by immersing the tube in a fluid bath to fill the tube, applying end plugs to the tube which are used to increase the internal pressure to a predetermined level and bending the tube along a plane perpendicular to the die stroke.
- the tube may be bent around a die to the desired configuration.
- the hydroforming process may also be used to radially expand sections of the tube by increasing the internal pressure at that region.
- hydroforming process provides in manipulating metal without deformation
- the complexity of the bent tube is limited by the dies used in the process.
- the known hydroforming processes bend the tube only in a single plane. Modern components are becoming increasingly complicated requiring compound bends.
- the hydroforming process lends itself to the formation of complex tubular products without deformation of the metal material.
- the present invention overcomes the disadvantages of the prior known methods of forming complex tubular members by providing a hydroforming process which prevents deformation of the tube in conjunction with a pair of die sets to form the complex configuration.
- the present invention is directed to a hydroforming process to form compound bends in a tubular member to be used in a vehicle manifold.
- vehicle manufacturers are designing engines which include manifold pipes bending through closely defined spaces. Add to this the pressure to manufacture such components in a cost effective manner while maintaining the highest standards of quality.
- the process and apparatus of the present invention facilitates the attainment of these objections.
- the hydroforming process of the present invention involves delivering a tubular blank to a fluid bath which fills the blank with a hydroforming fluid.
- the ends of the blank are plugged and the internal fluid pressure is increased to the desired level.
- the dies of a dual direction die press are sequentially brought into engagement with the pressurized tubular blank to first bend the tube along one plane and then another.
- a first set of upper and lower dies close around the blank to bend the tube in the vertical plane.
- a second set of horizontal dies are wedged between the upper and lower dies to spread them as the horizontal dies bend the tube in the horizontal plane.
- the vertical bends formed by the first die set will be formed in the horizontal dies so that the vertical bends are not deformed as the horizontal die set forms the second bend.
- FIG. 1 is a cross-sectional view of a hydroforming apparatus for manufacturing a tubular member for a vehicle manifold having a compound configuration
- FIG. 2 is a cross-sectional view of the apparatus with a tubular blank delivered to the apparatus;
- FIG. 3 is a cross-sectional view of the apparatus with the ends of the tubular blank plugged for increased internal fluid pressure
- FIG. 4 is a cross-sectional view of the apparatus with the first die set in contact with the tubular blank to bend the tube along first plane;
- FIG. 5 is a cross-sectional view of the apparatus with the finished tube removed from the apparatus.
- FIG. 6 is an end perspective of the die for forming the tubular member along the two bend planes.
- FIGS. 1 through 5 there is shown an apparatus 10 for the manufacture of complex tubular members in accordance with the present invention.
- the tubular members of the present invention are adapted for use as the exhaust or intake pipes of a vehicle manifold and include compound curvatures including "bend-on-bend" which can only be economically accomplished using the technology of the present invention.
- the bend-on-bend compound curvature of the tubular member can best be defined as an end of the tube in a first plane with an overlying bend in a second, typically perpendicular, plane.
- the hydroforming apparatus and process of the present invention reliably accomplishes the compound curvature necessary to form a vehicle manifold tube capable of fitting within modern engine compartments.
- the hydroforming apparatus 10 of the present invention includes a bath or pan 12 forming a reservoir for the hydroforming fluid 14.
- a pair of hydraulic cylinders 16 are disposed within the pan 12.
- the cylinders 16 are in fluid communication with a hydraulic power unit 18 which controls the reciprocal movement of a piston 20 within the cylinder 16.
- the piston 20 is connected to a rod 22 which extends from the cylinder housing 16 and has a plug 24 mounted to the exterior end of the piston rod 22.
- the plugs 24 of the hydraulic cylinders 16 are used to seal the ends of the tubular blank 100 to create an internal fluid pressure during the hydroforming process as will be subsequently described.
- a stationary lower die 26 Positioned within the pan 12 is a stationary lower die 26.
- the lower die 26 is supported by a bolster 28 beneath the pan 12 in order to withstand the stamping forces associated with the process.
- the lower die 26 forms a part of a first die set 30 which also includes upper die 32 movable into mating engagement with lower die 26.
- the first die set 30 forms the bends of the tubular member 100 along a first vertical plane.
- the upper die 32 is secured to a slide 34 which is used to move the upper die 32 vertically into stamping engagement.
- a splash shield 36 is provided on the upper die 32 to minimize the splash of fluid from the pan 12 during the stamping process.
- a second die set 40 is used to form bends along a second, typically perpendicular plane.
- the second die set 40 includes a first horizontal die 42 and a second horizontal die 44 which engage the tubular blank 100 from the sides.
- the upper and lower die set 30 includes a tooling configuration 46 which imparts a desired configuration on the tubular member 100.
- This tooling configuration 46 is disposed in a first, vertical plane which imparts bends along a first plane. Consequently, the second die set 40 must incorporate the bends along the vertical plane in order to receive the tubular member 100 along the second horizontal plane.
- the tubular member 100 will have a compound curvature including bend-on-bend configuration imposed by the sequential stamping of the die sets 30 and 40.
- the die sets 30,40 each include cooperating camming surfaces 50 along a corner edge.
- the surfaces 50 are used to wedge the second die set 40 between the first die set 30. With the first die set 30 closed on the tubular member 100, the second die set 40 is extended between the cam surfaces 50 of the first die set 30 to spread the first die set 30 and permit the second die set 40 to stamp the tubular member 100 along the second plane.
- both die sets 30 and 40 are utilized in the apparatus 10 in order to form the compound curvature. Additionally, a hydroforming process is used whereby a predetermined fluid pressure is maintained within the tubular member to prevent deformation during the dual stamping process. Without the internal pressure, the bend-on-bend compound curvature could not be reliably constructed.
- FIG. 1 shows the apparatus 10 in a stand-by position with the die sets 30,40 and the hydraulic cylinders 16 retracted.
- a tubular blank 100 is delivered to the pan 12 and immersed within the fluid 14 (FIG. 2).
- the fluid 14 may be any number of different fluids, preferably the fluid 14 is a hydraulic oil which will prevent corrosion of the part yet is compressible within the tubular member 100 to create the desired internal pressure.
- the plugs 24 are extended to engage the ends of the tubular member 100.
- the fluid pressure within the tube 100 is increased to the desired level to prevent deformation during the stamping operation. With the tubular member 100 secured and pressurized (FIG.
- the upper and lower die set 30 engages the tubular blank 100 to impart bends along a vertical plane and then the second die set 40 stamps the second bends on the tubular blank 100.
- the die sets 30,40 are fully retracted and the plugs 24 withdrawn to release the manifold tube 100.
- Subsequent trimming and cutting operations are performed at a separate station to ready the tubes 100 for incorporation into the manifold assembly.
- a manifold tube is manufactured in a reliable and economical manner which permits the incorporation of complex and compound curvatures to meet engineering specifications.
Abstract
Description
Claims (5)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/408,742 US5485737A (en) | 1994-03-07 | 1995-03-22 | Apparatus for hydroforming a vehicle manifold |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/207,570 US5471857A (en) | 1994-03-07 | 1994-03-07 | Process for hydroforming a vehicle manifold |
US08/408,742 US5485737A (en) | 1994-03-07 | 1995-03-22 | Apparatus for hydroforming a vehicle manifold |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US08/207,570 Division US5471857A (en) | 1994-03-07 | 1994-03-07 | Process for hydroforming a vehicle manifold |
Publications (1)
Publication Number | Publication Date |
---|---|
US5485737A true US5485737A (en) | 1996-01-23 |
Family
ID=22771124
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US08/207,570 Expired - Lifetime US5471857A (en) | 1994-03-07 | 1994-03-07 | Process for hydroforming a vehicle manifold |
US08/408,742 Expired - Lifetime US5485737A (en) | 1994-03-07 | 1995-03-22 | Apparatus for hydroforming a vehicle manifold |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US08/207,570 Expired - Lifetime US5471857A (en) | 1994-03-07 | 1994-03-07 | Process for hydroforming a vehicle manifold |
Country Status (5)
Country | Link |
---|---|
US (2) | US5471857A (en) |
JP (1) | JP2634384B2 (en) |
CA (1) | CA2143255C (en) |
DE (1) | DE19507611A1 (en) |
GB (1) | GB2287203B (en) |
Cited By (21)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5630334A (en) * | 1995-10-31 | 1997-05-20 | Greenville Tool & Die Company | Liquid impact tool forming mold |
US5715718A (en) * | 1996-02-27 | 1998-02-10 | Benteler Automotive Corporation | Hydroforming offset tube |
WO1998030354A1 (en) * | 1997-01-08 | 1998-07-16 | Northrop Grumman Corporation | Electromagnetically forming a tubular workpiece |
US5813266A (en) * | 1995-10-31 | 1998-09-29 | Greenville Tool & Die Company | Method of forming and piercing a tube |
US5901593A (en) * | 1998-01-26 | 1999-05-11 | Northrop Grumman Corporation | Making hydropress formblocks and dies utilizing stereolithography and liquid molding compounds |
US6089064A (en) * | 1999-02-26 | 2000-07-18 | Tauzer; Paul J. | Sliding plug for applying end loads during isostatic bulge forming |
US6098437A (en) * | 1998-03-20 | 2000-08-08 | The Budd Company | Hydroformed control arm |
US6209372B1 (en) | 1999-09-20 | 2001-04-03 | The Budd Company | Internal hydroformed reinforcements |
US6270126B1 (en) | 1998-01-08 | 2001-08-07 | Formrite Companies, Inc. | Hydroformed hose fittings and related hose assemblies |
US6305204B1 (en) | 2000-07-13 | 2001-10-23 | The Boeing Company | Bulge forming machine |
US6430812B1 (en) | 1997-08-28 | 2002-08-13 | The Boeing Company | Superplastic forming of tubing pull-outs |
US6434990B1 (en) | 1999-01-08 | 2002-08-20 | Formrite Companies, Inc. | Hose fitting and die for preparation |
US6510720B1 (en) | 2001-10-18 | 2003-01-28 | Hartwick Professionals, Inc. | Hydraulic pressure forming using a self aligning and activating die system |
US6510920B1 (en) | 1999-08-31 | 2003-01-28 | Dana Corporation | Vehicle exhaust system and method of manufacture |
AU764040B2 (en) * | 1998-01-08 | 2003-08-07 | Formrite Companies, Inc. | Hose fitting and die for preparation |
WO2005031239A1 (en) * | 2003-10-02 | 2005-04-07 | Behr Gmbh & Co. Kg | Charge-air cooler for motor vehicles |
US20070005046A1 (en) * | 1999-05-03 | 2007-01-04 | Lin J T | Methods and apparatus for presbyopia correction using ultraviolet and infrared lasers |
US20090235527A1 (en) * | 2007-12-13 | 2009-09-24 | Paul Degarate | method of manufacturing handguards |
US20120047978A1 (en) * | 2010-06-15 | 2012-03-01 | Walter Neumann | Method of manufacturing a valve housing |
CN102407255A (en) * | 2010-09-21 | 2012-04-11 | 吉林省车桥汽车零部件有限公司 | Production method of transition bridge bent tube of heavy-duty truck |
EP3702060A4 (en) * | 2018-02-14 | 2021-08-11 | Sanoh Industrial Co., Ltd. | Bending-forming die |
Families Citing this family (26)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5582052A (en) * | 1993-05-20 | 1996-12-10 | Benteler Industries, Inc. | Controlled time-overlapped hydroforming |
US6026570A (en) * | 1994-05-11 | 2000-02-22 | Zeuna-Staker Gmbh & Co., Kg | Method for producing an exhaust gas manifold for a multi-cylinder engine |
US6247552B1 (en) * | 1994-12-16 | 2001-06-19 | J. Eberspächer Gmbh & Co. | Air gap-insulated exhaust manifold |
DE19521849A1 (en) * | 1995-06-16 | 1996-12-19 | Eberspaecher J | Exhaust manifold with sheet metal shaped intake pipes |
US5901443A (en) * | 1996-03-29 | 1999-05-11 | Ford Motor Company | Method of making a manifold for an automotive heat exchanger |
DE19633760C2 (en) * | 1996-08-22 | 2001-11-15 | Forschungsges Umformtechnik | Hydroforming method and associated apparatus |
DE19642824A1 (en) * | 1996-10-17 | 1998-04-23 | Hermann Bartels | Method and device for deforming metal hollow profile workpieces |
US5992197A (en) * | 1997-03-28 | 1999-11-30 | The Budd Company | Forming technique using discrete heating zones |
DE19733473C2 (en) * | 1997-08-02 | 2000-07-06 | Daimler Chrysler Ag | Method and device for producing a connection of a lambda probe holder to an exhaust pipe |
US6070445A (en) * | 1997-10-29 | 2000-06-06 | Trw Inc. | Method of manufacturing the control arm |
US6006568A (en) * | 1998-03-20 | 1999-12-28 | The Budd Company | Multi-piece hydroforming tool |
DE19829577B4 (en) * | 1998-07-02 | 2005-06-16 | Carsten Dipl.-Ing. Binder | Method and device for producing parts by means of internal high-pressure forming technology |
US6032501A (en) * | 1999-02-09 | 2000-03-07 | The Budd Company | Method of hydroforming multi-lateral members from round tubes |
DE19955506B4 (en) * | 1999-11-18 | 2006-05-04 | Alcan Technology & Management Ag | Method for forming an initial profile or the like. Workpiece as well as profile for it |
DE19955694A1 (en) | 1999-11-18 | 2001-05-23 | Alusuisse Tech & Man Ag | Process for forming an initial profile or the like workpiece and profile therefor |
JP4554812B2 (en) * | 2000-12-25 | 2010-09-29 | ヤマハ発動機株式会社 | Exhaust pipe |
DE10102896B4 (en) * | 2001-01-23 | 2004-01-15 | Benteler Automobiltechnik Gmbh | Process for the production of an exhaust manifold |
US6912884B2 (en) * | 2001-06-25 | 2005-07-05 | Mohamed T. Gharib | Hydroforming process and apparatus for the same |
US7266982B1 (en) * | 2005-06-10 | 2007-09-11 | Guza David E | Hydroforming device and method |
CA2693332C (en) | 2007-07-20 | 2013-01-15 | Nippon Steel Corporation | Method for hydroforming and a hydroformed product |
US9044802B2 (en) * | 2010-03-26 | 2015-06-02 | Weatherford Technology Holdings, Llc | Dynamic load expansion test bench and method of expanding a tubular |
CN103286181B (en) * | 2013-04-25 | 2016-07-06 | 芜湖众力底盘系统有限公司 | The bending method of automobile chassis component connecting rod |
CN103506495A (en) * | 2013-10-12 | 2014-01-15 | 芜湖开瑞金属科技有限公司 | Bending and forming die for automobile hollow lifting hook |
CN103506494A (en) * | 2013-10-12 | 2014-01-15 | 芜湖开瑞金属科技有限公司 | Bending forming die for solid lifting hook of automobile |
CN103878241B (en) * | 2013-11-20 | 2016-02-03 | 无锡曙光模具有限公司 | The edge-cutting and hole-punching mould of automobile engine exhaust system inlet manifold |
CN110576088B (en) * | 2019-08-29 | 2021-01-26 | 四川航天长征装备制造有限公司 | 90-degree bending forming method and device for large-diameter thin pipe |
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- 1994-03-07 US US08/207,570 patent/US5471857A/en not_active Expired - Lifetime
-
1995
- 1995-02-22 GB GB9503468A patent/GB2287203B/en not_active Expired - Fee Related
- 1995-02-23 CA CA002143255A patent/CA2143255C/en not_active Expired - Fee Related
- 1995-03-04 DE DE19507611A patent/DE19507611A1/en not_active Withdrawn
- 1995-03-06 JP JP7045585A patent/JP2634384B2/en not_active Expired - Fee Related
- 1995-03-22 US US08/408,742 patent/US5485737A/en not_active Expired - Lifetime
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Cited By (35)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5974846A (en) * | 1995-10-31 | 1999-11-02 | Greenville Tool & Die Company | Method of forming and piercing a tube |
US5813266A (en) * | 1995-10-31 | 1998-09-29 | Greenville Tool & Die Company | Method of forming and piercing a tube |
US5630334A (en) * | 1995-10-31 | 1997-05-20 | Greenville Tool & Die Company | Liquid impact tool forming mold |
US5715718A (en) * | 1996-02-27 | 1998-02-10 | Benteler Automotive Corporation | Hydroforming offset tube |
WO1998030354A1 (en) * | 1997-01-08 | 1998-07-16 | Northrop Grumman Corporation | Electromagnetically forming a tubular workpiece |
US5826320A (en) * | 1997-01-08 | 1998-10-27 | Northrop Grumman Corporation | Electromagnetically forming a tubular workpiece |
US6860517B2 (en) | 1997-08-28 | 2005-03-01 | The Boeing Company | Tubular metal part having pullouts |
US6612020B2 (en) | 1997-08-28 | 2003-09-02 | The Boeing Company | Apparatus for superplastic forming of tubing |
US6430812B1 (en) | 1997-08-28 | 2002-08-13 | The Boeing Company | Superplastic forming of tubing pull-outs |
US6270126B1 (en) | 1998-01-08 | 2001-08-07 | Formrite Companies, Inc. | Hydroformed hose fittings and related hose assemblies |
US6658909B2 (en) * | 1998-01-08 | 2003-12-09 | Formrite Companies, Inc. | Hose fitting and die for preparation |
US6619698B2 (en) | 1998-01-08 | 2003-09-16 | Formrite Companies, Inc. | Hose fitting and die for preparation |
AU764040B2 (en) * | 1998-01-08 | 2003-08-07 | Formrite Companies, Inc. | Hose fitting and die for preparation |
US6047580A (en) * | 1998-01-26 | 2000-04-11 | Northrop Grumman Corporation | Making hydropress formblocks and dies utilizing stereolithography and liquid molding compounds |
US5901593A (en) * | 1998-01-26 | 1999-05-11 | Northrop Grumman Corporation | Making hydropress formblocks and dies utilizing stereolithography and liquid molding compounds |
US6098437A (en) * | 1998-03-20 | 2000-08-08 | The Budd Company | Hydroformed control arm |
US6434990B1 (en) | 1999-01-08 | 2002-08-20 | Formrite Companies, Inc. | Hose fitting and die for preparation |
US6089064A (en) * | 1999-02-26 | 2000-07-18 | Tauzer; Paul J. | Sliding plug for applying end loads during isostatic bulge forming |
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US8464566B2 (en) * | 2010-06-15 | 2013-06-18 | Buerkert Werke Gmbh | Method of manufacturing a valve housing |
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CN102407255B (en) * | 2010-09-21 | 2015-02-11 | 吉林省车桥汽车零部件有限公司 | Production method of transition bridge bent tube of heavy-duty truck |
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Also Published As
Publication number | Publication date |
---|---|
CA2143255A1 (en) | 1995-09-08 |
GB2287203A (en) | 1995-09-13 |
DE19507611A1 (en) | 1995-09-21 |
CA2143255C (en) | 1998-03-31 |
GB2287203B (en) | 1997-01-08 |
GB9503468D0 (en) | 1995-04-12 |
JPH0819820A (en) | 1996-01-23 |
US5471857A (en) | 1995-12-05 |
JP2634384B2 (en) | 1997-07-23 |
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